System for controlling water used for industrial food processing

ABSTRACT

A method and a control system for water used in a food processing system are provided. For example, the control system includes at least one sensor configured to collect a sensor signal from a produce handling device, a logic processor configured to receive the sensor signal collected by the at least one sensor and generate a control signal for controlling adding wash solution to the water used in the food processing system, and a human machine interface (HMI) configured to display information from the logic processor to a user.

CLAIM OF PRIORITY UNDER 35 U.S.C. § 119

The present Application for Patent claims benefit of U.S. ProvisionalPatent Application Ser. No. 62/403,322 filed on Oct. 3, 2016, assignedto the assignee hereof and hereby expressly incorporated by referenceherein.

BACKGROUND Field of the Disclosure

The subject matter disclosed herein generally relates to food processingand, more particularly, to controlling water chemistry used forindustrial food processing.

Description of Related Art

Water is used in many food processes. For example, water is often usedto wash produce at different stages of processing. In many cases thiswater is recycled and used multiple times. This is particularly true ofthe wash processes including those used in the value added produceindustry. It is important to assure that this water does not add to thefood safety hazards that might be associated with the food beingprocessed. Accordingly, the water is controlled and monitored using anumber of different methods and system to try and reduce any food safetyconcerns. The control requirements will vary with the food product beingprocessed and the process.

Water chemistry management has been evolving with increased automationand improvements in instrumentation. There are still operations that usetest strips and manual wet chemistry methods but these are increasinglyinadequate. To address these needs, more sophisticated controllers havecome into play with more logic. Even with these developments, moreefficient and reliable approaches are needed. It is also increasinglyimportant to validate control.

SUMMARY

The systems, methods, apparatus, and devices of the disclosure each haveseveral aspects, no single one of which is solely responsible for itsdesirable attributes. Without limiting the scope of this disclosure asexpressed by the claims which follow, some features will now bediscussed briefly. After considering this discussion, and particularlyafter reading the section entitled “Detailed Description” one willunderstand how the features of this disclosure provide advantages thatinclude improved food safety.

Certain aspects provide a control system for controlling water used in afood processing system. The control system generally includes at leastone sensor configured to collect a sensor signal from a produce handlingdevice, a logic processor configured to receive the sensor signalcollected by the at least one sensor and generate a control signal forcontrolling adding wash solution to the water used in the foodprocessing system, and a human machine interface (HMI) configured todisplay information from the logic processor to a user.

Certain aspects provide a control system for controlling water used in afood processing system. The control system generally includes at leastone processor configured to execute computer readable instructions. Thecomputer readable instructions include collecting, using a sensordisposed at the food processing system, a sensor signal, generating oneor more control signals for controlling one or more chemical pumps andone or more valves to provide a wash solution into the water of the foodprocessing system based on the sensor signal, and transmitting the oneor more control signals to the one or more chemical pumps and one ormore valves. The control system may further include a memory coupled tothe at least one processor and configured to store one or more of thecomputer readable instructions, the one or more control signals, and thesensor signal.

Certain aspects provide a non-transitory computer program product forcontrolling water used in a food processing system. The non-transitorycomputer program product generally includes a computer readable storagemedium having program instructions embodied therewith. The programinstructions, executable by a processor, cause the processor to collect,using a sensor disposed at the food processing system, a sensor signal,generate, using a processor, one or more control signals for controllingat least one of a fouling control device, one or more chemical pumps,and one or more valves of a control system to provide a wash solutioninto the water based on at least the sensor signal, and operate at leastone of the fouling control device, the one or more chemical pumps, andthe one or more valves based on the one or more control signals.

Aspects generally include methods, apparatus, systems, computer readablemediums, and processing systems, as substantially described herein withreference to and as illustrated by the accompanying drawings. Numerousother aspects are provided.

To the accomplishment of the foregoing and related ends, the one or moreaspects comprise the features hereinafter fully described andparticularly pointed out in the claims. The following description andthe annexed drawings set forth in detail certain illustrative featuresof the one or more aspects. These features are indicative, however, ofbut a few of the various ways in which the principles of various aspectsmay be employed, and this description is intended to include all suchaspects and their equivalents.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above-recited features of the presentdisclosure can be understood in detail, a more particular description,briefly summarized above, may be had by reference to aspects, some ofwhich are illustrated in the appended drawings. It is to be noted,however, that the appended drawings illustrate only certain typicalaspects of this disclosure and are therefore not to be consideredlimiting of its scope, for the description may admit to other equallyeffective aspects.

FIG. 1 is a block diagram of a control system for water used in produceprocessing that includes a water control system and produce washequipment, in accordance with certain aspects of the present disclosure.

FIG. 2 is a block diagram of a control system for water used in produceprocessing with examples of sensor placement, in accordance with certainaspects of the present disclosure.

FIG. 3 is a block diagram of a control system for water used in produceprocessing showing examples of network integration, in accordance withcertain aspects of the present disclosure.

FIG. 4 is a block diagram of a control system for water used in produceprocessing with examples of data storage memory locations, in accordancewith certain aspects of the present disclosure.

FIG. 5 is a block diagram of a control system for water used in produceprocessing with distributed processing control, in accordance withcertain aspects of the present disclosure.

FIG. 6 is a block diagram of a control system for water used in produceprocessing including pumps controlled by control signals, in accordancewith certain aspects of the present disclosure.

FIG. 7 is a block diagram of a control system for water used in produceprocessing that controls water pH for washing produce, in accordancewith certain aspects of the present disclosure.

FIG. 8 is a block diagram of a pH Clean-In-Place (CIP) enclosure of acontrol system for water used in produce processing, in accordance withcertain aspects of the present disclosure.

FIG. 9 is a block diagram of a control system for water used in produceprocessing that controls chlorine being added to the water for washingproduce, in accordance with certain aspects of the present disclosure.

FIG. 10 is an illustration of a set of filters used in a control systemfor water used in produce processing, in accordance with certain aspectsof the present disclosure.

FIG. 11 is a flow chart of a method for using a control system for waterused in produce processing, in accordance with certain aspects of thepresent disclosure.

FIG. 12 is a block diagram of a control system with cleaning andcalibration elements used in produce processing, in accordance withcertain aspects of the present disclosure.

FIG. 13 is a block diagram of a control system with cleaning andcalibration elements and a filter used in produce processing, inaccordance with certain aspects of the present disclosure.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures. It is contemplated that elements disclosed in one aspectmay be beneficially utilized on other aspects without specificrecitation.

DETAILED DESCRIPTION

Aspects of the present disclosure provide apparatus, methods, processingsystems, and computer readable mediums for controlling water chemistryused for industrial food processing.

The following description provides examples, and is not limiting of thescope, applicability, or examples set forth in the claims. Changes maybe made in the function and arrangement of elements discussed withoutdeparting from the scope of the disclosure. Various examples may omit,substitute, or add various procedures or components as appropriate. Forinstance, the methods described may be performed in an order differentfrom that described, and various steps may be added, omitted, orcombined. Also, features described with respect to some examples may becombined in some other examples. For example, an apparatus may beimplemented or a method may be practiced using any number of the aspectsset forth herein. In addition, the scope of the disclosure is intendedto cover such an apparatus or method which is practiced using otherstructure, functionality, or structure and functionality in addition toor other than the various aspects of the disclosure set forth herein. Itshould be understood that any aspect of the disclosure disclosed hereinmay be embodied by one or more elements of a claim. The word “exemplary”is used herein to mean “serving as an example, instance, orillustration.” Any aspect described herein as “exemplary” is notnecessarily to be construed as preferred or advantageous over otheraspects.

As shown and described herein, various features of the disclosure willbe presented. Various embodiments may have the same or similar featuresand thus the same or similar features may be labeled with the samereference numeral, but preceded by a different first number indicatingthe figure to which the feature is shown. Thus, for example, element “a”that is shown in FIG. X may be labeled “Xa” and a similar feature inFIG. Z may be labeled “Za.” Although similar reference numbers may beused in a generic sense, various embodiments will be described andvarious features may include changes, alterations, modifications, etc.as will be appreciated by those of skill in the art, whether explicitlydescribed or otherwise would be appreciated by those of skill in theart.

Embodiments described herein are directed to a system and method forcontrolling a wash solution in a wash system for produce handling. Forexample, according to one or more embodiments, a system and methodinclude data collection using one or more sensors and generating controlsignals, based on the collected data, to control chemical pumps thatadjust the amount of one or more chemicals in water used to wash producethat is being processed. The system can also include user input data aswell has historical databases and analysis that can be used to generatethe control signals. The control signals can also be generated based onthe collected data, stored data, analysis, user input, a combination ofdata types, and/or other related data. Further, the control signals canalso be generated for fouling the sensors and related components basedon the collected data, stored data, analysis, user input, a combinationthereof, and/or other related data. Additionally, the control signalscan further include scheduling the fouling based on the collected data,stored data, analysis, user input, a combination thereof, and/or otherrelated data.

According to one or more cases, a number of elements are included in acontrol system for a value added produce wash system. Some of theseelements relate to monitoring water attributes while others relate tothe performance of the monitoring system itself. Other elements relateto monitoring the status of the food process.

For example, in some cases, the control system may include at least twochannels of monitoring. These channels provide control to allow controlof a primary stage and secondary stage present in many wash systems. Insome cases, one or more pH monitoring devices for each stage may beprovided. A pH monitoring device can include an electrode that issuitable for a food contact situation. One or more coulometric chlorineelectrodes for each stage may be provided in some cases. The effluentfrom such electrodes is often dumped rather than returned to use. Insome cases, temperature monitoring for correcting pH measurements andchlorine measurements based on projected values of both when at thattemperature may be provided.

In some cases, another element that may be included in an apparatus,system, and/or method for controlling a wash solution in a wash systemfor produce handling includes a relay to stop product feed if chlorineis out of specification for either stage. Similarly, product feed may behalted if pH is outside of the desired range. In some cases, a wired orwireless full duplex data communication with basic trend monitoring andreporting may be provided. Further, in some cases, another element thatcan be included is a memory location for storing all or some of thecollected data along with other indicators. The data stored can includea subset of select data that is being collected. For example, key datacan be backed up locally with a USB flash drive.

According to one or more cases, an electrode fouling control systemincluding filtration and specific fouling removal processes may beincluded. Fault trapping in data analysis, may be used to monitor thewater flow by a pH electrode and a chlorine electrode. Additionally, inone or more embodiment, it may be useful to insure that a foulingcontrol device, for example a Clean-In-Place (CIP) air pressure device,is present and that water is circulating in the wash system.

In other cases, other fouling control devices such as clean-in-placeembodiments may be provided that include flushing an electrode/sensorwith a liquid wash solution such as, for example, an acid solution orsome other food safe cleaning agent. A single clean-in-place device maybe provided that is connected to each electrode such that the device isable to provide the cleaning air/gas and/or liquid as described herein.In another case, the clean-in-place device may be configured such thatit can be connected when needed and disconnected from eachelectrode/sensor when not needed. In another case, each electrode/sensormay have its own specific clean-in-place device connected to theelectrode/sensor. The clean-in-place device may therefore containcleaning solution that is specifically tailored for theelectrode/sensor. Further the device may further provide the ability toalso provide a calibration solution when selected. Additionally, in somecases, when the clean-in-place device provides pressurized air/gas forcleaning, the pressure can be tailored specifically for theelectrode/sensor to which the device is connected.

According to one or more cases, one or more touch screen interfaces canbe provided for user input in the wet environment of a plant and allowssubstantial flexibility in input locations. Alternatively, a traditionalmouse and/or keyboard can be provided. Further, microphones could beprovided to capture audio commands and/or cameras can be included tocapture user gestures that can correspond to select inputs and definedby the user and understood by the system.

According to some cases, another element that can be included is a relaythat stops chlorine addition of the pH exceeds a threshold. For example,a facility safety is enhanced if there is a relay provided that can stopchlorine addition if the pH exceeds 7, which can be defined as a domainoutside of the normal operating conditions. Similarly, one can set alower bound to prevent or reduce the hazards of chlorine outgassing.

Further, additional elements can be included in the system and/or methodfor controlling a wash solution in a wash system for produce handling.For example, in accordance with one or more embodiments, sensor data andanalysis data generated using the sensor data can be stored in memorysomewhere in or connected to the system. Further, control signals andoperational parameters can be generated and stored in memory as well. Inaccordance with one or more embodiments, a firewall panel is included inthe system to allow external systems to view what is stored in thememory or database such as operational parameters without access tocontrol features. Accordingly, the firewall panel can preventunauthorized changes in operating parameters. In one or more cases, amemory coupled to at least one processor may be configured to store oneor more of computer readable instructions, one or more control signals,and one or more sensor signals.

A graphical user interface may be shown on a computer display that auser, such as a machine operator, plant supervisor, etc., uses to viewthe data from the database such as the sensor data and operationalparameters. However, the firewall panel prevents the user from inputtingcontrol signals by discarding any input from the user that attempts toadjust the operational parameters and/or is detected by the firewallpanel as a disallowed input.

A web portal interface that may be provided to a user that is off-sitesuch as a customer or corporate company leadership. When the userconnected using the web portal over the internet from a remote locationin relation to the position of the system, the user is give certainprivileges. For example, the user can be provided with access to viewdata stored in a database of the system. However, a firewall panel canbe provided that disallows the user from inputting control commands thatattempt to, for example, change the operational parameters of thesystem. Thus, the user is can be granted viewer rights only through theuse of the firewall panel. According to another embodiment, the firewallpanel can provide some control of certain select items such requestingthat following of the sensors be executed, or that new data points becollected by the sensors and processed. In another embodiment, thefirewall panel can prevent all action and only provide the user visualaccess.

A system and/or method for controlling a wash solution and pH deviationsmay be provided. A pH deviation includes using a pH sensor and a pHchemical pump. For example, a pH deviation to a desired value can bedetected by the pH sensor. This data can then be analyzed to determineand generate a control signal that defines the operating parameters of apH chemical pump. The signal is then transmitted to the pH chemical pumpwhich adjusts the amount of chemical based on the reviewed data in orderto balance out the data from the sensor readings.

One or more sensors and controllers may be added to the product feedcontrol loop to more stringently control the proceeding operations inaccordance with one or more cases. Additionally, full feedback isreported to the controller about the status of product feed to assurethat the control relay is not circumvented and prevent inappropriateprocessing. The controller assesses whether the product feed is asexpected given the status of the water chemistry.

A split line control may be provided in accordance with one or morecases. This element may allow the two control channels to control eithera two-stage wash line, a one-stage wash line or two one-stage lines.According to other embodiments, additional channels can be included inexcess of two.

According to one or more cases, a proportional integral derivative (PID)controller with, for example 5 to 10 second control loops can be used tocontrol the chemical pumps of the overall system. This allows the systemto maintain the desired control and consistency in the water chemistry.The PID controller further allows for slow and fast acting sanitizerchanges and better tuning of control. Further, according to one or moreembodiments, controlling the speed of response provided the controlsystem the ability to vary the degree of anticipation and response thatcorresponds with the produce wash equipment specification and/or producecharacteristics. For example, cleaning carrots can sometimes be donewith a longer respond time to chemical amount shifts while onionsrequire a faster response to changes detected by one or more sensors.The control system can set the pump frequency and/or rate and strokelength to control the amount of chemical added as well as the timing.Further, a time interval may be selected for pumping based on the sensorprovided information.

A redundant transient storage solution may be provided that can providedata integrity and protection, in accordance with one or more cases. Forexample, a two tiered backup solution can be implemented that uses localstorage devices and a USB drive that can be plugged into any of thecontrol system elements and then move and plugged into another element.

According to one or more cases, sensor fouling with limited interruptionof data for cleaning may be provided that improves the fouling controlsystem. According to one or more embodiments, a number of differentelements can be provided that increase effectiveness. For example,switching from an elapsed time clock to a daily clock for chlorineelectrode electrochemical cleaning can be provided. This change in clockcycle insures that the chlorine electrodes may start each day ofproduction without fouling. According to another embodiment, anotherelement that can be provided is adding feedback to the controller toconfirm that chlorine electrode was cleaned allowing verification ratherthan assuming the cleaning cycle was complete. Further, according toanother embodiment another element that can be included is cascading adesigned for purpose filter. This may include a set of cascading filtersthat may include a first filter connected in parallel with a secondfilter. These filters may be of a tangential flow design to extendoperating time. This allows greater tolerance for interfering materialsincluding fats and oils that are present in meat and poultry operations.

According to other cases, to increase the utility of the system and thecloud based data, more powerful analysis tools may be added andcalibration data collected. According to one or more embodiments, acalibration report is generated to statistically guide the decision toadjust the output from the chlorine system to accurately report chlorineconcentration without correction that just add noise to the data stream.The cloud data from multiple plants and lines allows development ofmetric for performance comparisons such as degree of control, hours ofin control operation and the absence of outliers. According to anotherembodiment, the cloud based data can be used to generate certificates ofperformance to demonstrate that the line was operating correctly.

Given the importance of particle removal to fouling control of theelectrodes, it is instructive to examine the filtration in greaterdetail that can be provided in accordance with one or more embodiments.For example, according to one or more embodiments, the filter housingand design look familiar but the fluid flow has been changed to provideby-pass flow to continuously clear the faces of the screens and filtersas shown in FIG. 10 below. According to one or more embodiments, whenfilters of this type are cascaded they are even more effective andprovide longer operating windows before cleaning is necessary. Thisfiltration coupled with Clean-In-Place (CIP) airflow, or anotherclean-in-place device, is enough to maintain the pH electrodes. Thecoulometric chlorine electrode requires electrochemical cleaning.

In accordance with one or more embodiments, the improved calibrationprocess uses a calibration and verification process to assure theaccuracy of the sensor electrodes. Further, according to one or moreembodiments, a new controller can be put into service when the electroderesponse has drifted to outside of the acceptable range as determine bythe verification process which utilizes a t-test as a decision makingtool (the ratio of the difference to variance corrected for the numberof measurements). This data can be manually entered into the cloud datasystem where the reporting decision reports the results reducing thehuman decisions.

Plumbing and electrical layout of one or more cases are illustrated inFIGS. 7, 8, and 9. These diagrams assist in organizing the flow ofinformation and data in this complex system.

Turning now to FIG. 1, as shown, FIG. 1 is a block diagram of a controlsystem 100 for water used in produce processing, which may be called awater control system or an Automated Smart Wash Analytical Platform(ASAP) 100, and a produce wash equipment 150, which may also be referredto herein as a produce handling device 150, in accordance with one ormore embodiments. As shown a control system 100 includes a logicprocessor 110 that can also be called a controller 110. The logicprocessor 110 is provided such that is can communicate and receive datafrom all the other elements of the control system 100. The logicprocessor 110 can also take the received data from other elements of thecontrol system (such as the HMI 140, sensor 120, and pump 130), or fromdevices as location outside the control system 100 (such as the producehandling equipment 150 or other external devices or databases). Inaccordance with one or more embodiments, the logic processor/controller110 can take any of the received data or subset thereof and process thedata to generate analysis output that can be provided to the HMI 140 fordisplay to a user. Additionally the data can be used by the controller110 for generating control signals for controlling elements connected tothe controller 110.

For example, according to one or more embodiments, the logic processor110 receives sensor data from at least the sensor 120, user input fromthe HMI 140 from one or more users, and data from the pump 130. Thelogic processor 110 can also receive data from the produce handlingequipment 150. Further the logic processor 110 can also receive datafrom other control systems, or other databases. The logic processor 110then takes all or part of this received data and generates controlsignals that can be transmitted to one or more of the other elements ofthe control system 100.

Physically, the logic processor 110 can be implemented using a selectnumber of logic circuit elements that can be integrated into one or moreother physical devices in the overall control system 100 or even withinan element of the produce handling equipment 150 or combination thereof.For example, a physical processing core can be integrated into thesensor 120 or in the HMI 140 that serves as the logic processor 110. Inanother example, a processing core can be provided in the pump 130 or inthe produce handling equipment 150. In another embodiment the logicprocessor 110 can be a stand-alone computing system. This can includebut is not limited to an on-site server, an off-site server, adistributed server arrangement, a cloud computing system, a portableelectronic device, and/or a combination.

The control system 100 also include a human machine interface (HMI) 140that is connected to the logic processor 110 such that the HMI 140 canreceive and provide data to and from a user and the logic processor 110.The HMI 140 can be for example, but is not limited to, a touchscreen, amonitor, a speaker system, a combination thereof, and/or any otherdevice capable of transmitting and receives data from a user. Forexample, the HMI 140 can be a stationary computer station, a mobilecomputing device such as a tablet, cellular phone, laptop, and/orwearable electronic. The HMI 140 can also be a speaker system such as astationary speaker system mounted in a facility or an integrated speakersystem in an electronic device. Further, the HMI 140 can be acombination of electronic display, sound, and camera devices. An HMI 140that includes one or more camera devices can receive inputs from a userin the form of gestures or movements. Also the HMI 140 can include amicrophone so that is can receive audio input from a user. Further, theHMI 140 can receive input from the user using a keyboard, mouse, ortouchscreen as well. The HMI 140, when implements as a mobile device,can also receive input in the form of a movement, such as a shake orwaving of the device by a user, that is detected by movement sensors inthe mobile device. The HMI 140 can then provide one or more of thereceived inputs to the logic processor 110. Further, in anotherembodiment, the HMI 140 can process the data and provide the results ofthe processing to the logic process 110 in an effort to alleviate theprocessing load on the logic processor 110.

The control system may include at least one sensor 120. As shown, inother embodiments the control system 100 can include a plurality ofsensors. In one embodiment, the sensor 120 can be a pH sensor that candetect a pH level in a fluid that is run through the sensor. The fluidcan be the wash solution that includes water and possibly other chemicaland debris from the produce handling equipment 150. In anotherembodiment, the sensor 120 can be a chlorine sensor that detects achlorine level in the fluid that is run through the sensor. Further, inother embodiments, the sensor 120 can be a temperature gauge, amicrophone, an imaging device such as a camera or video camera, or otherknown sensors. Further, a plurality of sensors can be included that canall be providing collected data to the logic processor 110. The sensor120 can be provided elsewhere, near, adjacent to, attached to, and/orwithin the produce handling equipment 150. For example, the sensor 120can be located at a distance from the produce handling equipment 150while being connected using a sampling hose that transports the fluid tobe tested to the sensor 120. In another embodiment, the sensor can beprovided connected to or within the produce handling equipment 150.

Additionally, the control system 100 may include at least one pump 130.In other embodiments, the control system 100 and include a plurality ofpumps. The pump 130 can be a chemical pump that pumps a select washsolution into the water of the produce handling equipment that is beingused to wash produce being processed. For example, the pump 130 can be apH solution pump, or in another embodiment a chlorine pump. The pump 130can also pump a wash solution that includes a number of chemical. Thepump 130 receives control signals from the logic controller 110 thatindicate to the pump when to pump, for how long to pump, and how fastthe pump should operate.

FIG. 2 is a block diagram of a control system 200, or ASAP 200, forwater used in produce processing with examples of sensor placement inaccordance with one or more embodiments. As shown, the control system200 includes a logic processor 210 that is connected to a human machineinterface 240 as well as a plurality of sensors 221, 222, 223, and 224.The sensors 221, 222, 223, and 224 are each shown at a differentrepresentative location in relation to produce handling equipment 250that the sensors 221, 222, 223, and 224 are monitoring. The sensors 221,222, 223, and 224 can be placed as shown at all different locations, allat any one positions, or a combination thereof.

Looking specifically at each of the sensors, a sensor 221 can beprovided away from the produce handling equipment 250. For example, a pHor chlorine sensor can be placed at a location and be connected to theequipment 250 using a sampling hose that carries water from theequipment 250 to the sensor 221. In another embodiment, the sensor 221can be a camera or microphone. This arrangement allows for the controlsystem 200 to be provided at a central testing location to be installedin a plant setting away from any of the produce handling equipment linesin the plant. Sensor 222 can be placed adjacent to or connected to theproduce handling equipment 250. For example, a sensor can be mounted onthe outside of the produce handling equipment were the sensor 222 can bedirectly provided samples or inputs for testing. The sensor 223 isprovided such that part of the sensor can extend into the producehandling equipment 250. For example, sensor 223 can be mostly mounted toan outer surface of the produce wash equipment with a probe extendinginto the equipment 250. Further, sensor 224 shows that a sensor can beprovided completely within or submerged in the produce handlingequipment 250.

FIG. 3 is a block diagram of a control system 300, or ASAP 300, forwater used in produce processing showing examples of network integrationin accordance with one or more embodiments. As shown the control system300 includes a logic processor 310, a HMI 340, and sensors 321, 322,323, and 324 provided to collected data from produce handling equipment350. The HMI 340 is similar to the above discussed HMI 140 of FIG. 1.Similarly, sensors 321, 322, 323, and 324 are similar to sensors 221,222, 223, and 224 of FIG. 2. Further, the control system now includesone or more networks 361 and 361 that can be used to connect elements ofthe control system 300 that are no longer directly connected with thelogic processor 310. Specifically, as shown a network 361 can be used toconnect sensors 321, 322, 323, and 324 to the logic processor 310. Forexample, the network 361 can include a local area network (LAN) andassociated device resources that provide a communication path for thesensors to communicate with the logic processor. The network 361 can bea wired system, a wireless system, or a combination thereof. The network361 can also be a wide area network (WAN) or even can represent aconnection through the internet that would traverse a number of networkelements now included in the network 361. This allows for the placementof the logic processor 310 to effectively be placed anywhere.

Further, the system 300 includes a network 362 as well that connects theHMI 340 and the logic processor 310. The network 362 can include a localarea network (LAN) and associated device resources that provide acommunication path for the HMI 340 to communicate with the logicprocessor. The network 362 can be a wired system, a wireless system, ora combination thereof. The network 362 can also be a wide area network(WAN) or even can represent a connection through the internet that wouldtraverse a number of network elements now included in the network 362.This allows for the placement of the logic processor 310 and the HMI 340to effectively be placed anywhere. For example, the HMI 340 could be aportable electronic device that the user carries with them within theplant or even outside the plant. Similarly, the logic processor 310 canbe located on-site, off-site, or a combination thereof.

FIG. 4 is a block diagram of a control system 400, or ASAP 400, forwater used in produce processing with examples of data storage memorylocations in accordance with one or more embodiments. The control system400 includes a HMI 440, a logic processor 410, sensors 421, 422, 423,and 424, and networks 461 and 462 that are similar to the similarelements in FIGS. 2 and 3. Specifically, the HMI 240, logic processor210, sensors 221, 222, 223, and 224 from FIG. 1 and networks 361 and 362from FIG. 2, respectively.

Further, the control system can include one or more of the shown memorydevices or locations. The memory devices can be provided in the form ofintegrated random access memory (RAM), read-only memory (ROM), a cache,or any other known memory arrangement. These integrated memory elementscan be provided as, for example, a static integrated circuit, a harddrives, floppy disc, optical drive, or any other known memory type.Further, the memory devices can also be stand along memory devices inthe form of USB data drives or external hard drives or even distributedcloud computing storage solutions. For example, looking specifically atFIG. 4, the HMI 440 can include a memory device 440.1. This memorydevice 440.1 can be a universal serial bus (USB) thumb drive, anintegrated or external hard drive, or any other memory device and/orcombination thereof. Additionally, according to one or more embodiments,control system 400 elements can include a plurality of memory devices.For example, the logic processor 410 can include a first memory device410.1 and can also include a second external memory device 410.2. Thefirst memory device 410.1 can be an internal form of memory while thesecond memory device 410.2 can be an external memory device such as aUSB thumb drive. Further, according to one or more embodiments, any oneof the sensors 421, 422, 423, and 424 can each also include one or moreforms of memory devices 421.1, 422.1, 423.1, and 424.1 as shown.Further, according to one or more embodiments, an external detachablememory element, such as a USB thumb drive 421.1, can be detached from asensor 421 and can then be directly connected to another device such asthe logic processor 410 transferring the data from the memory device421.1 to the logic processor 410. This process can also be done in thereverse carrying data such as control signals to a sensor or otherdevice in the system.

FIG. 5 is a block diagram of a control system 500, or ASAP 500, forwater used in produce processing with distributed processing control inaccordance with one or more embodiments. The control system 500 includesa HMI 540, and sensors 521, 522, 523, and 524. In other embodiments thecontrol system 500 can have more or less sensors and their placement canalso vary as well as their type. In this embodiment the logicprocessor/controller is explicitly show has a distributed system.Specifically the control system 500 can include a number of logicprocessors 511, 512, and 513. As shown the logic processor 512 forexample can handle a subset of the sensors. For example, the logicprocessor 512 can be connected to chlorine sensors 523 and 524 in thesystem and can therefore conduct all the specific data processingassociated with the type of sensor data. The logic processor 513 is showto connect with a different subset of sensors. For example, the logicprocessor 513 can connect to pH sensors 522 and 521 found in the system.The logic processors 512 and 513 can then send specifically processeddata to the logic process 511 which can conduct additional overarchingprocessing and send that to be displayed to a user using the HMI 540.

According to other embodiments, there can be include more or less logicprocessors than those shown. For example each sensor can have its ownlogic processor or any variation thereof can be provided. Further,according to other embodiments, the logic processor 512 and logicprocessor 513 may connect to sensors not based on their type but ratheranother characteristic such as location or processing requirements toproduce a specifically desired output.

FIG. 6 is a block diagram of a control system 600, or ASAP 600, forwater used in produce processing including control signals and pumpsthat are controlled by the control signals in accordance with one ormore embodiments. Specifically, as shown, the control system 600includes one or more pumps 631, 632, 633, and 634. According to one ormore embodiments, the chemical feed pump 631 can be provided away from,adjacent to, partially within, or totally within the produce handlingequipment 650. Further, according to other embodiments, the pumps 632,633, and 634 can be provided at different location as well. One or moreof the chemical pumps 631, 632, 633, and 634 can pump produce washchemicals such as chlorine and/or a combination of chemicals that makeup a was solution. For example, a commercial system for a two stageleafy green wash line might include six pumps to allow control ofchlorine in each stage, and two additional pumps to control an acid washadjuvant that is suitable for organic or conventional productionallowing for ease in line conversion from organic to conventionalproduction. The reverse conversion can also be done but it is lessuseful because a full wash down is required to prevent carry over intothe organic production.

Further the control system 600 includes a logic processor 610 thatreceives data from one or more sensors 621, 622, 623, and 624. The logicprocessor 610 can also receive data from a HMI 640. Further, the logicprocessor 610 can receive data from one or more of the chemical feedpumps 631, 632, 633, and 634. The logic processor 610 can then take allor part of the received data and process the data to come up withcontrol signals. The control signals can then be transmitted to, forexample, the chemical feed pumps instructing the pump on when and howmuch to pump. For example, consider a leafy green processing lineoperating at a 15 ppm setpoint. As the chlorine levels begin to fall dueto product flow and reaction, the controller will activate the chlorinepump. As the demand grows, the PID will begin anticipating the demandprompting greater and/or longer activation of the pump with the goal ofmaintaining a stable chlorine concentration in the wash system. Similarcontrol will be exercised to control the pH.

FIG. 7 is a block diagram of a control system 700, or ASAP 700, forwater used in produce processing that controls water pH for washingproduce in accordance with one or more embodiments. The control system700 includes a wash solution 781 reservoir that contains chemicals forwashing produce such as sodium hypochlorite or SmartWash Solutions SW™or any other materials that needs to be dosed into the line in acontrolled manner. The control system 700 also includes a primary pHpump 721.1 that pumps the wash solution 781 into the produce handlingequipment 750 and specifically into the water being using in the producehandling equipment 750 to wash the produce. The control system 700 alsoincludes a secondary pH pump 721.1 that can also pump wash solution 781into the produce handling equipment. Additional pumps can be added ifwash solutions 781 is to be added at other locations in the producehandling equipment 750. Further the control system 700 can furtherinclude a second wash solution 782. This wash solution can be, forexample, an organic wash solution. The control system can furtherinclude a primary organic pH pump 722.1 and a secondary organic pH pump722.2 that are each able to pump the wash solution 782 into the producehandling equipment at different points and at different timing andamounts as indicated by received control signals generated by thecontrol system.

Specifically, the control system 700 further includes a first sensorpHE-1 725.1 and a second sensor pHE-2 725.2 that are sensors that candetect and provide pH sensor data to a logic processor of the controlsystem 700. The control system 700 can then take these sensor data andgenerate control signals for controlling the pumps 721.1, 721.2, 722.1and 722.2. As shown, water samples from the produce handling equipment750 are drawing into and through the sensors 725.1 and 725.2 that thenoutput the pH sensor data for processing and/or storage. Further, thecontrol system 700 includes a pH clean-in-place (CIP) enclosure 770. TheCIP enclosure 770 is connected to the first and second sensors 725.2 and725.2 and facilitates and conducts cleaning of itself and the sensorswhich is specifically described in FIG. 8.

FIG. 8 is a block diagram of a pH Clean-In-Place (CIP) enclosure 770 ofa control system/ASAP, for water used in produce processing inaccordance with one or more embodiments. As shown the CIP enclosure 770is connected to both pH sensors 725.1 and 725.2. The CIP enclosure 770includes internal solenoids 774 and 776 that are configured to control aflow path using valves 775 and 777 respectively. A cleaning air blastcan be used to clean out either of the flow paths 775 and 777.Particularly, according to one or more embodiments, solenoids 774 and776 control the valves 775 and 776 respectively when a cleaning event istriggered. The signal to command the solenoids to open the valves comesfrom the PLC. In some cases, an air blast device may be configured todeliver a filtered and oil free burst of air to dislodge adheringmaterial on at least one sensor.

The CIP enclosure 770 further includes a Pressure Transmitter (PT) 773that sends a signal to the PLC with the measurement of the air pressurein the CIP system. This measurement can be used to send an alarm thatthere is too much or too little air to function correctly. Further, theCIP enclosure 770 includes a filter 771 that protect an air regulator772. The air regulator 772 regulates the air pressure to the desiredoperating pressure.

FIG. 9 is a block diagram of a control system 900, or ASAP 900, forwater used in produce processing that controls chlorine being added tothe water for washing produce in accordance with one or moreembodiments. The control system 900 includes a sensor enclosure 926 thatincludes a primary flow cell 926.1 sensor and a secondary flow cell926.2 sensor. The control system 900 further includes a primary filter991 and a secondary filter 992 that is connected to the sensor enclosure926. These filters 991 and 992 are connected to the produce handlingequipment 950. The filters 991 and 992 pull water from the producehandling equipment 950 and filter the water discarding of some whilepassing the filtered water into the sensor enclosure 926 and into theprimary and secondary flow cell sensors 926.1 and 926.2. The sensors926.1 and 926.2 can then process the provided water, generate a sensorsignal, and transmit that sensor signal out to a controller of thecontrol system 900. The sensor signals can indicate the amount or lackthereof, of chlorine present in the water. The controller can generatecontrol signals based on this sensor data and can provide those controlsignals to the primary and secondary chlorine pumps 923.1 and 923.2. Thechlorine pumps include a primary chlorine pump 923.1 and a secondarychlorine pump 923.2. The primary chlorine pump 923.1 and the secondarychlorine pump 923.2 pull the chlorine solution 983 in accordance withthe control signals each receive and provide that chlorine solution intothe water in the produce handling equipment 950.

FIG. 10 is an illustration of a set of filters 1090 used in a controlsystem for water used in produce processing in accordance with one ormore embodiments. For example, the set of filters 1090 can be as one orboth of the filters 991 and 992 as shown in FIG. 9. The set of filters1090 include at least two sub-filters 1098 and 1099 that are connectedin series with the output of a first filter 1098 feeding into the inputof the second filter 1099. Initially, process water 1090.1 is input intothe first filter 1098 as shown. Particles and water return 1090.2 thatare collected by the filtering agent within the filter 1098 arediscarded. Next, a stream of partially filtered water 1090.3 is outputfrom the first filter 1098 and into the second filter 1099. The secondfilter again filters out particles and water and discards of the secondset of particles and water 1090.4. What is left is prepared processwater 1090.6 that is passed to one or more filters for testing of thewater for chemical composition.

FIG. 11 is a flow chart of operations 1100 for using a control systemfor controlling water used in produce processing in accordance with oneor more embodiments. The operations 1100 includes collecting, using asensor disposed at the food processing system, a sensor signal(operation 1102). The operations 1100 also includes generating one ormore control signals for controlling one or more chemical pumps and oneor more valves to provide a wash solution into the water of the foodprocessing system based on the sensor signal (operation 1104). Theoperations 1100 further include transmitting the one or more controlsignals to the one or more chemical pumps and one or more valves(operation 1106).

In spite of recent advances in wash process control as discussed herein,there are still challenges. Oft times, the control systems as describedherein may be operated in cold and/or wet environments. Suchenvironments may be deleterious to the performance of electroniccomponents. Failure of these potentially critical electronic componentsmay present a potential food safety hazard. The control of wash processis critical to many food processing operations. Manual control isincreasingly inadequate. Therefore wash process control is increasinglyhandled by control systems such as described herein in one or moredisclosed embodiments and examples. Further, additional features may beprovided that may further improve and care for instrumentation asdescribed herein that is used to manage wash processes.

In accordance with one or more cases, chlorine monitoring andmaintenance may be improved through the implementation of, for example,calibration and/or electrode cleaning. The importance and mechanics ofchlorine electrode calibration are described herein. However, chlorineelectrodes and flow cells can be fouled by deposits that can tan toblack in color. These deposits can be cleaned manually by disassemblyand manual scrubbing with an acid cleaner. Although this may be anadequate way to end up with a clean sensor, the process and need to stopthe produce processing, remove, disassemble, reassembly, and reinstallthe sensor. This is not only time consuming but also costly and imposesboth wear and tear on the sensor parts such as the electrodes as well asprovides a complex disassemble/assemble procedure that may lead toerroneous implementation leading to sensor damage and possible foodsafety concerns.

According to one or more cases, a feature that may be provided is aclean-in-place option that avoids the disassembly and manual scrubbing.For example, a general example of this is shown in FIG. 7 element 770. Aspecific implementation is further shown in FIG. 8. Other cases areshown in FIGS. 12 and 13 that include other specific examples thatinclude passing a liquid cleaning and/or calibration solution throughthe electrodes/sensors. An oxidizing acid solution will rapidly dissolvedeposits that may be found on or near an electrode flow cell. Manyoxidizing acids are known including but not limited to nitric acid,chromic acid, and peroxy acids of various organic acids. In some cases,a peroxy acetic acid for cleaning may be selected because the acid iscommercially available in food grade qualities making it highlycompatible with use in a food processing environment.

Turning now to FIG. 12, a block diagram of a control system 1200 withcleaning and calibration elements used in produce processing is shown.The control system 1200 includes a fluid receptacle that contains acleaning solution connected to a primary cleaning solution dosing pump1. The dosing pump 1 is further connected to a multi-way selector valve7. The control system also includes a calibration solution connected toa calibration solution dosing pump 2. The dosing pump 2 is furtherconnected to the multi-way selector valve 7. In addition to receivingcleaning solution and calibration solution, the selector valve 7 alsoreceives sample water. The selector valve 7 can switch between any ofthese options and provide a selected flow to an electrode flow cell. Inone or more cases, the control system 1200 may also include an optionaldosing pump 3 and an optional multi-way valve 5 that provide cleaningsolution to a secondary electrode flow cell. Further, the control system1200 may include another optional dosing pump 4 and another optionalmulti-way valve 6 for providing calibration solution to the secondaryelectrode flow cell.

FIG. 13 is a block diagram of a control system 1300 with cleaning andcalibration elements identical to FIG. 12. The control system 1300 mayfurther include a filter that filters the incoming sample water that isthen provided to the electrode flow cell. The filter may also include areturn water path. In some cases, the water filter may be included thatis configured to filter sample water provided to at least one sensor andreturn excess sample water when a multi-way valve is engaged to provideat least one of a cleaning solution or a calibration solution to the atleast one sensor instead of the sample water.

In one or more cases, peroxy acetic acid is gentle enough thatdeleterious effects on the electrode and housing may not be apparentover a broad range of concentrations including up to 50%. However, 50%may be much more concentrated than necessary to achieve the cleaning ofthe electrode. At the lower end, the cleaning time begins to increasebelow about 2% when the electrode and housing are between 40 and 80degrees F. At less than about 0.5% the cleaning is less complete inreasonable times. In accordance with one case, a recommended cleaning istherefore 2% peroxy acetic acid for 15 minutes to overnight. In othercases, time, temperature, and concentration can be adjusted against eachother to generate other cleaning protocols. This embodiment is simpleand effective for use in most process environments where chlorinemonitoring is performed with the referenced automated system.

To gain further improvements in the maintenance process for suchcontrollers, the use of a solution can be automated with robotic valvescontrolled by a controller such as a PLC or by manual selection. Theability to select between process water, no flow, cleaning solution suchas the described 2% solution, and calibration solution may reduce theneed for human intervention during the regular activities of cleaningand calibration. It accordance with one or more cases, control may beachieved through a series of binary valves or a single multichannelvalve. The decision between options may be based on the cost andreliability of the components as well as sensor feedback values.

In one or more cases, in a steady state operation, the electrode andflow cell are placed in the cleaning solution for 15 minutes or more.The solution is made static but switched to no flow to allow cleaning tooccur after about three volumes of solution have flushed the system. Thesolution could be allowed to flow continuously but this is not required.At start up the electrode and flow cell are reconnected to process waterto flush the system. As the line systems all stabilize, the calibrationsolution is selected to confirm the calibration or initiate acalibration is needed. When this is completed, the flow of process wateris restored to return to normal automation. These procedures may beimplemented using the system 1200 presented in FIG. 12.

Additionally, the maintenance of these machines, devices, and systemstakes people and scheduling. Time spent on maintenance is time a line isnot producing product. Accordingly it can be appreciated that automationof the maintenance activities has impacts beyond just the labor savings.In one case, a robotic valve may used to select the delivery of processwater, calibration solution, or electrode cleaning solution allowingincreased automation in maintenance activities.

The environment where these control systems operate can be verychallenging. The moist air, the changing temperatures, and the sanitarywash downs are threats to the reliability of the control systemelectronics.

Thus, in one or more cases, the electronics of the controller are heldunder pressure greater than ambient with dry air to retard watermigration. Specifically, electronics may be housed in cabinets designedfor this purpose with appropriate gasketed doors and cable openings tomitigate the entry of these environmental conditions. For example, inone or more cases, a small positive pressure, about 4 inches of water,with dry air may be provided which may mitigate threats to reliabilityby preventing the ingress of moisture and moist air. In accordance withone or more cases, adding air pressure to the electronic cabinets of anASAP may help prevent moisture entry and prevent mold growth. Forexample, pressurized enclosure may be provide for logicprocessors/controllers 110, 210, 310, 410, 511, 512, 513, and 610 asshown in FIGS. 1-6. Additionally, a pressurized enclosure may also beprovided for the human machine interfaces as well as for any of theelectronics of sensors as disclosed herein. Further, pressurizedenclosures may be provided for memory devices as shown, for example, inFIG. 4.

These improvements can be used in tandem or individually to improve thereliability of wash process control equipment.

While the present disclosure has been described in detail in connectionwith only a limited number of embodiments, it should be readilyunderstood that the present disclosure is not limited to such disclosedembodiments. Rather, the present disclosure can be modified toincorporate any number of variations, alterations, substitutions,combinations, sub-combinations, or equivalent arrangements notheretofore described, but which are commensurate with the scope of thepresent disclosure. Additionally, while various embodiments of thepresent disclosure have been described, it is to be understood thataspects of the present disclosure may include only some of the describedembodiments.

The term “about” is intended to include the degree of error associatedwith measurement of the particular quantity based upon the equipmentavailable at the time of filing the application. For example, “about”can include a range of ±8% or 5%, or 2% of a given value.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the presentdisclosure. As used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,element components, and/or groups thereof.

While the present disclosure has been described with reference to anexemplary embodiment or embodiments, it will be understood by thoseskilled in the art that various changes may be made and equivalents maybe substituted for elements thereof without departing from the scope ofthe present disclosure. In addition, many modifications may be made toadapt a particular situation or material to the teachings of the presentdisclosure without departing from the essential scope thereof.

Therefore, it is intended that the present disclosure not be limited tothe particular embodiment disclosed as the best mode contemplated forcarrying out this present disclosure, but that the present disclosurewill include all embodiments falling within the scope of the claims.

What is claimed is:
 1. A control system for controlling water used in afood processing system, the control system comprising: at least onesensor configured to sense a produce handling device and generate asensor signal; a fouling control device connected to the at least onesensor, wherein the fouling control device comprises: an air blastdevice configured to deliver a filtered and oil-free burst of air todislodge adhering material on the at least one sensor; at least onevalve connected to the at least one sensor, wherein the fouling controldevice is configured to deliver a cleaning solution using the at leastone valve to dissolve the adhering material on the at least one sensor;a set of cascaded filters coupled to the at least one valve andincluding a first filter connected in series with a second filter,wherein the first filter and the second filter are of a tangential flowdesign; and a calibration solution device configured to deliver acalibration solution to the at least one valve; a logic processorconfigured to receive the sensor signal generated by the at least onesensor and generate a control signal for controlling adding a washsolution to the water used in the food processing system, based on thesensor signal; and a human machine interface (HMI) configured to displayinformation from the logic processor.
 2. The control system of claim 1,further comprising: at least one pump that is configured to receive thecontrol signal from the logic processor and pump the wash solution intothe water in the food processing system based on the control signal. 3.The control system of claim 2, wherein the at least one pump isconfigured to pump the wash solution for a time interval as defined bythe control signal.
 4. The control system of claim 2, wherein the atleast one pump is configured to pump the wash solution at a frequency asdefined by the control signal.
 5. The control system of claim 2, whereinthe at least one pump is configured to pump a particular amount of thewash solution as defined by the control signal.
 6. The control system ofclaim 2, wherein the logic processor is further configured to: receive adata input from one or more users using the human machine interface; andgenerate the control signal based also on the data input.
 7. The controlsystem of claim 1, wherein the set of cascaded filters is connectedbetween the food processing system and the at least one sensor.
 8. Thecontrol system of claim 1, wherein the set of cascaded filters isconfigured to filter sample water provided to the at least one sensorand return excess sample water when the at least one valve is engaged toprovide at least one of the cleaning solution or the calibrationsolution to the at least one sensor instead of the sample water.
 9. Thecontrol system of claim 1, wherein the fouling control device connectedto the at least one sensor further comprises: a fluid receptacle thatcontains the cleaning solution; and a dosing pump connected to the fluidreceptacle, wherein the fouling control device is configured to deliverthe cleaning solution using the dosing pump and the at least one valveto dissolve the adhering material on the at least one sensor.
 10. Thecontrol system of claim 1, wherein the cleaning solution comprises fromabout 0.5% to about 2% peroxy acetic acid.
 11. The control system ofclaim 1, wherein the logic processor is configured to receive feedbackdata from the food processing system and generate the control signalalso based on the feedback data.
 12. The control system of claim 1,further comprising: data handling devices that include one or more of aUSB drive, an internal drive, a static memory device, and a networkconnection to local storage or to cloud storage.
 13. The control systemof claim 1, further comprising: a memory configured to store one or moreof the control signal, the sensor signal, and computer-readableinstructions, wherein the logic processor is further configured toexecute the computer-readable instructions, the computer-readableinstructions comprising: receiving the sensor signal; generating thecontrol signal based on the sensor signal; generating a sensor cleaningcontrol signal based on the sensor signal; operating the fouling controldevice connected to the at least one sensor; and transmitting the sensorcleaning control signal to the at least one valve.
 14. The controlsystem of claim 13, wherein the computer-readable instructions furthercomprise: receiving the control signal at a pump; and pumping the washsolution for at least one of a set time, frequency, or amount based onthe control signal.
 15. A computer program product for controlling waterused in a food processing system, the computer program productcomprising a computer-readable storage medium having programinstructions embodied therewith, the program instructions executable byat least one processor to cause the food processing system to: receive asensor signal from a sensor disposed at the food processing system;generate one or more control signals for controlling a fouling controldevice and at least one of one or more chemical pumps or one or morevalves of a control system to provide a wash solution into the waterbased on the sensor signal; and operate the fouling control device andthe at least one of the one or more chemical pumps or the one or morevalves based on the one or more control signals, wherein the foulingcontrol device comprises: an air blast device configured to deliver afiltered and oil-free burst of air to dislodge adhering material on thesensor; at least one valve connected to the sensor, wherein the foulingcontrol device is configured to deliver a cleaning solution using the atleast one valve to dissolve the adhering material on the sensor; a setof cascaded filters coupled to the at least one valve and including afirst filter connected in series with a second filter, wherein the firstfilter and the second filter are of a tangential flow design; and acalibration solution device configured to deliver a calibration solutionto the at least one valve.